MDP 482s_Metrology & Measuring Instruments

Thread Measurements

Dr.Tamer Hassan Sayed

Tamer.Hassan@eng.asu.edu.eg
 Lecture Outline
• Threads’ Classification, Manufacturing, Geometry, and Terminology.

• External Thread Measurements:

o E.1-Major Diameter Measurement.
• E.1.1- Using Hand Tools.
• E.1.2- Using Abbe Vertical Metroscope.
• E.1.3- Using Tool Maker's Microscope.

o E.2-Minor Diameter Measurement.

• E.2.1- Using Hand Tools.
• E.2.2- Using Tool Maker's Microscope.

o E.3-Pitch Diameter Measurement.

• E.3.1- Using Hand Tools.
• E.3.2- Using Abbe Vertical Metroscope.
• E.3.3- Using Tool Maker's Microscope. 2
 Lecture Outline
o E.4-Included Angle Measurement.
• E.4.1- Using Hand Tools.
• E.4.2- Using Abbe Vertical Metroscope.
• E.4.3- Using Tool Maker's Microscope.

o E.5-Flank Angle Measurement.

• E.5.1- Using Tool Maker's Microscope.

o E.6-Pitch Measurement
• E.6.1- Using Tool Maker's Microscope.

• Thread Limit Gauges.

• Thread Errors.

• Summary, Review Questions, and Problems. 3

 Introduction
Threads are classified according to:
1.Form of the surface SPSRFF
• Straight
• Taper: gas and liquid tubes, self sealing, fast clamping
• Horizontal: Jaw Chuck
2.Form of Profile
• Triangular
• Trapezoidal
• Square
• Round
• Worm
4
 Thread Classification (cont.)
3.no. of starts
• Single lead is the total distance covered in one revolution
• Double in single thread lead and pitch are equal
• Multi in two start thread pitch is half of lead
and in 4 start pitch would be one forth of lead
4.Sense of rotation
in multi start effort could be reduced for opening
• Right hand RH and closing the bolt as axial movement is
• Left hand LH advanced.
And in multi start strength is also increased by
5.Function providing more number of threads.

• Fastener
• Power Screw
6.Fines
• Coarse pitch: high loads.
• Fine pitch.
5
 6

ISO Metric Thread

Whitworth Thread

6
 Thread Manufacturing

• Turning
• Rolling
• Milling
• Tapping
• Casting

7
Thread Geometry

8
8
 Thread Terminology

P/2

P/2

9
9
 Terminology
1- Screw thread: It’s a continuous helical groove of specified cross-section
produced on the external or internal surface.

2- Crest: It’s the top surface joining two sides of thread.

3- Flank: It’s the surface between crest and root.

4- Root: The bottom of the groove between the two flanks of the thread.

5- Lead: Lead = number of starts * pitch

6- Pitch: The distance measured parallel to the axis from a point on a thread to
the corresponding next point.

10
7- Helix angle: It’s the angle made by the helix of the thread at the pitch line
with the axis.

8- Flank angle: It’s the angle made by the flank with the perpendicular to the
thread axis.

9- Depth of thread: The distance between the crest and the root of the thread.

10- Included angle: Angle between the flanks of a thread measured in an axial
plane.

11
1- Metric Thread:
• Metric Thread is Specified according to the French Standard.
• The Included angle of the Metric Thread is 60°.
• The Metric Thread is Specified as M ø * p.
Where: (ø) is the External Diameter of Thread and (p) is the Pitch of the
Thread measured in (mm).

12
2- Whitworth Thread:
• Whitworth Thread is Specified according to the British Standard.
• The Included angle of Whitworth thread is 550.
• The Whitworth Thread is Specified as W ø * p.
Where (ø) is the outer Diameter of the Thread (inch) and ( p ) is the
number of (teeth/inch).

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External Thread Measurements

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E.1-Major Diameter Measurement

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 E.1.1- Using Hand Tools
Tools:
1- External Micrometer.
2- Two pieces of block gauge

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 Procedure

Note:
1- Zero error.
2- Misalignment error (Cosine error).

17
 E.1.2- Using Abbe Vertical Metroscope
1-Steel wire
2-Spindle clamp
3-Spiral ocular
4-Eye piece
5-Wheel
6-Locking screw
7-Measuring anvil
8-Measuring stage
9-Work piece
10-Base
11-Threaded column
12-Dash pot
13-Light source
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How To Read?

53.175 mm

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Tools:
1- Two pieces of block gauge.

Procedure:
1- Take initial reading with the anvils closed on the two block gauges (Ri).
2- Take the final reading on the block gauges with the thread (Rf).
3- Thread major diameter = Rf – Ri .
4- Repeat step (2) along the thread.

20
E.1.3- Using Tool Maker's Microscope
1) Base
2) X & Y micrometers.
3) Rotary table.
4) Object lens.
5) Microscope tube.
6) Reading eyepiece.
7) Ocular head axes’ eyepiece.
8) Ocular head support.
9) Bracket.
10) Rotating hand wheel.
11) Column.
12) Locking screw.
13) Pivot.
14) Bottom illumination light source.
15) Tilting protractor. 21
Tools :
A set of block gauges, thread gauge and two centers fixture.

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 Tool Maker's Microscope Adjustments
1- Adjust the focus. HOW?

23
 Tool Maker's Microscope Adjustments
2- Be sure that the ocular head’s axes coincide with the table axes. HOW?

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 Tool Maker's Microscope Adjustments
3- Be sure that the light source is perpendicular to the table surface.
HOW?

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 Tool Maker's Microscope Adjustments
4- Be sure that the thread axis is aligned with the table X-axis. HOW?

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Procedure

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E.2-Minor Diameter Measurement

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E.2.1- Using Hand Tools

𝐷𝑖𝑛. = 𝑅𝑒𝑎𝑑𝑖𝑛𝑔 ∗ cos 𝜓

𝑃𝑖𝑡𝑐ℎ
tan 𝜓 =
𝜋 𝐷𝑒𝑓𝑓.
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 E.2.2- Using Tool Maker's Microscope

Note: Helix angle!!!

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 31

Shadow Elimination

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E.3-Pitch Diameter Measurement

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 E.3.1- Using Hand Tools
Tools:
Thread micrometer, external micrometer, thread gauge and a set of
standard wires.

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Three Wire Method

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Three Wire Method

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 Best Wire Diameter
𝑃 𝑃
𝐴𝐵 = , 𝐶𝐵 =
2 4

From Triangle OBC

➔ Angle OBC = ϴ & OB = r

𝐶𝐵 𝑃 𝑃
cos ϴ = = ➔r= sec ϴ
𝑂𝐵 4𝑟 4

𝑷
➔ Best wire diameter = dbest = 𝒔𝒆𝒄 ϴ
𝟐

36
 𝑷
S = De + d (1 + cosec𝜽) - 𝒄𝒐𝒕𝜽
𝟐
S= Reading over wires
37
From Triangle ABD➔
𝐴𝐵
sin 𝜃 = ,
𝐴𝐷
AB = r ➔ AD = r cosec 𝜽

From Triangle DEF ➔

𝑃𝑖𝑡𝑐ℎ
EF =H, DE = ,
2
𝐷𝐸 𝑃 𝑃 𝐻 𝑷
tan𝜃 = = ➔H = 𝑐𝑜𝑡𝜃, CD= ➔ CD = 𝒄𝒐𝒕𝜽
𝐸𝐹 2𝐻 2 2 𝟒
𝑃
h = AD – CD = r cosec𝜃- 𝑐𝑜𝑡𝜃
4

Distance over wires = S = De + 2h + 2r

𝑷
S = De + d (1 + cosec𝜽) - 𝒄𝒐𝒕𝜽
𝟐
38
 E.3.2- Using Abbe Vertical Metroscope
Tools:
1- Thread Gauge.
𝑷
2- A set of standard wires. dbest = 𝒔𝒆𝒄 𝛉
𝟐

𝑷
S = De + d (1 + cosec 𝛉) - 𝒄𝒐𝒕𝛉
𝟐
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E.3.3- Using Tool Maker's Microscope

What is the effect of Helix angle?

40
 Elimination of Shadow Effect

Use knife technique to eliminate the shadow effect.

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Elimination of Shadow Effect

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Misalignment Elimination

𝒅𝟐𝟏 + 𝒅𝟐𝟐
Pitch Diameter =
𝟐

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E.4-Included Angle Measurement

44
 E.4.1- Using Hand Tools
Tools:
1- External Micrometer.
2- A set of standard wires.

𝒅𝒘𝟐 −𝒅𝒘𝟏
sin 𝜽 =
(𝒀𝟐 −𝒅𝒘𝟐 )− (𝒀𝟏 −𝒅𝒘𝟏 )

𝜽 = Half the included angle

45
 E.4.2- Using Abbe Vertical Metroscope
Tools:
1- A set of standard wires.

𝒅𝒘𝟐 −𝒅𝒘𝟏
sin 𝜽 =
(𝒀𝟐 −𝒅𝒘𝟐 )− (𝒀𝟏 −𝒅𝒘𝟏 )

𝜽 = Half the included angle

46
E.4.3- Using Tool Maker's Microscope

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E.5-Flank Angle Measurement

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E.5.1- Using Tool Maker's Microscope

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 Misalignment Elimination

𝜽𝟑 +𝜽𝟒 𝜽𝟏 +𝜽𝟐
𝜽𝒓 = , 𝜽𝒍 = Applied also for included angle
𝟐 𝟐
50
E.6-Pitch Measurement

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E.6.1- Using Tool Maker's Microscope

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53

53
Misalignment Elimination

𝑵𝒐. 𝒐𝒇 𝒔𝒕𝒂𝒓𝒕𝒔?

𝑳𝟏 +𝑳𝟐 +𝑳𝟑 +𝑳𝟒

𝟒
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Thread Limit Gauges

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 56

To Check an External Thread

56
 57

Thread Ring Gauge

GO NO GO

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 58

Thread Caliper Gauge

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 59

To Check an Internal Thread

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Thread Plug Gauge

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Thread Errors

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 Thread Errors

To find out the accuracy of a screw thread, it’ll be necessary to measure

the following parameters:

1) Major diameter.
2) Minor diameter.
3) Pitch diameter.
4) Pitch.
5) Flank angle or Included angle.

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 Effect of Included angle Error on De
P= Pitch, ø= Half the included angle, ϴ= Half the anvil angle &
δ= Error in measured pitch diameter.
𝑃Τ 𝑃
𝑡𝑎𝑛𝜃 = 2
➔ 𝑍 = 𝑐𝑜𝑡𝜃
𝑧 2

𝑃Τ 𝑃
𝑡𝑎𝑛𝜙 = 2
➔𝑍+𝛿 = 𝑐𝑜𝑡𝜙
𝑍+𝛿 2

𝑷
∴𝜹= 𝒄𝒐𝒕𝝓 − 𝒄𝒐𝒕𝜽
𝟐

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 64

Effect of Flank Angle Error on 𝑫𝒆

64
 𝐺𝐷 𝐺𝐷
𝑠𝑖𝑛𝜃 = ∴ 𝐸𝐷 =
𝐸𝐷 𝑠𝑖𝑛𝜃
𝐹𝑜𝑟 𝑠𝑚𝑎𝑙𝑙 𝛿𝜃 𝑟𝑎𝑑.
𝑠𝑖𝑛𝛿𝜃 ≈ 𝛿𝜃, 𝐴𝐷 ≈ 𝐴𝐶
𝐺𝐷 𝐺𝐷
= = 𝛿𝜃
𝐴𝐷 𝐴𝐶
𝛿𝜃
∴ 𝐺𝐷 = 𝐴𝐶𝛿𝜃 𝑎𝑛𝑑 𝐸𝐷 = 𝐴𝐶
𝑠𝑖𝑛𝜃
𝐴𝐵 𝐴𝐵
= 𝑐𝑜𝑠𝜃 ∴ 𝐴𝐶 =
𝐴𝐶 cos 𝜃
𝑩𝒖𝒕 𝑨𝑩 = 𝒉𝒂𝒍𝒇 𝒕𝒉𝒆 𝒕𝒐𝒐𝒕𝒉 𝒅𝒆𝒑𝒕𝒉(𝑺𝑻𝑹𝑨𝑰𝑮𝑯𝑻 𝑷𝑶𝑹𝑻𝑰𝑶𝑵)

ℎ 𝛿𝜃 ℎ𝛿𝜃
∴ 𝐸𝐷 = =
2 𝑐𝑜𝑠𝜃 𝑠𝑖𝑛𝜃 𝑠𝑖𝑛2𝜃
𝒉
∆𝑫𝒆 = 𝜹𝜽𝑹𝒊𝒈𝒉𝒕 + 𝜹𝜽𝑳𝒆𝒇𝒕
𝒔𝒊𝒏𝟐𝜽 65
65
 66

𝒉
∆𝑫𝒆 = 𝜹𝜽𝑹𝒊𝒈𝒉𝒕 + 𝜹𝜽𝑳𝒆𝒇𝒕
𝒔𝒊𝒏𝟐𝜽
δθ in radian, h in mm ➔ ∆𝑫𝒆 in mm.

∆𝑫𝒆 = 𝟎. 𝟎𝟏𝟑𝟏 ∗ 𝑷 ∗ 𝜹𝜽𝑹𝒊𝒈𝒉𝒕 + 𝜹𝜽𝑳𝒆𝒇𝒕

For ISO metric thread, δθ in degrees and P = nominal pitch mm
➔ ∆𝑫𝒆 in mm.

∆𝑫𝒆 = 𝟎. 𝟎𝟏𝟎𝟓 ∗ 𝑷 ∗ 𝜹𝜽𝑹𝒊𝒈𝒉𝒕 + 𝜹𝜽𝑳𝒆𝒇𝒕

For Whitworth thread, δθ in degrees and P
= nominal pitch (inch) ➔ ∆𝑫𝒆 in inch.

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 Corrections for Rake error & Elastic Compression
𝑃
Reading over wires = S = De + d (1+cosec𝜃) - 𝑐𝑜𝑡θ
2
𝑃
De = S - d (1 + cosec 𝜃) + 𝑐𝑜𝑡𝜃
2
Corrected De = De – Rake error + Compression error
𝑐𝑜𝑠𝜃𝑐𝑜𝑡𝜃 𝑙2
Rake error = ∗ ∗ 𝐴2 1 + 𝐴𝑠𝑖𝑛𝜃 + 𝐴2 𝑠𝑖𝑛2 𝜃 ➔ mm
2𝜋2 𝑑
Where: 𝜃=Half the included angle, l = lead, d = wire diameter,
A = d/(T+d),T= reading under wires = S-2d.
2
𝐹3
Compression error = 0.001 ∗ 1 ➔ mm
𝐷𝑒 3

Where: F= measuring force in N, De = Pitch diameter in mm

67
67
Pitch

68
68
 Effect of Pitch Error on Pitch Diameter
∆𝑃
ac =
2

∆𝐷𝑒
𝑎𝑏 =
2

From triangle abc

𝑎𝑐
tan 𝜃 = ➔ ab = ac * cot 𝜃
𝑎𝑏

∴ ∆𝑫𝒆 = ∆𝑷𝒎𝒂𝒙. ∗ 𝒄𝒐𝒕𝜽

69
69
Thread Pitch Errors

70
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Progressive error: the pitch of the thread is longer or
shorter than its nominal value.

Causes:
1-Incorrect linear and angular
velocity ratio.
2-Incorrect gear train or an
approximate gear train
between w.p. and lead screw.

71
71
Periodic error: are repeated at regular intervals along
the thread.
Max. Cumulative Pitch
Error Causes:
1-Un-uniform tool-work
velocity ratio. (Not constant).
2-Teeth error in gears.
3-Lead screw error. (Axial
Movement).

72
72
Drunken error: is found inside the thread tooth. Pitch
measured parallel to the thread axis will be accurate.

If the thread is not cut to the true helix, the Drunken

thread error will be formed.

73
73
Irregular error: Varies in irregular manner along the
length of the thread.

Causes:
1- Machine fault.
2- Non-Uniformity in the material.
3- Machining disturbances.

74
74
Accumulated Pitch Error

75
75
 76

Virtual Effective Diameter

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Summary

77
77
 Major Diameter Measurement

In our laboratory, the thread major diameter will be measured

using:

1) External micrometer.
2) Abbe Vertical Metroscope.
3) Tool Maker's Microscope.

78
78
 Minor Diameter Measurement

In our laboratory, the thread minor diameter will be measured

using:

1) Thread micrometer with the help of block gauges.

2) Tool Maker's Microscope.

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79
 Pitch Diameter Measurement

In our laboratory, the thread pitch diameter will be measured using:

1) Thread Micrometer.
2) External Micrometer with the help of standard wires.
3) Abbe Vertical Metroscope with the help of standard wires.
4) Tool Maker's Microscope.

80
80
 Pitch Measurement

In our laboratory, the thread pitch will be measured using:

1) Tool Maker's Microscope.

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81
 Included Angle Measurement

In our laboratory, the thread included angle will be measured using:

1) External Micrometer with the help of standard wires.

2) Abbe Vertical Metroscope with the help of standard wires.
3) Tool Maker's Microscope.

Included angle can be roughly estimated using thread gauge.

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82
 Flank Angle Measurement

In our laboratory, the thread flank angle will be measured using:

1) Tool Maker's Microscope.

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83
Review Questions

84
84
 What …

1. are the important thread elements to be checked?

2. is meant by the best size wire?
3. are the different corrections to be applied in the measurement of the
pitch diameter by the three wires method?
4. is the difference between Pitch diameter and Virtual effective
diameter?
5. are the different types of pitch error in threads?
6. is meant by the rake and compression corrections.

85
85
 86

Explain …

1. how the effect of misalignment could be eliminated in T.M.M.

experiment for measuring thread pitch and flank angles.
2. thread drunken pitch error and its causes.
3. thread periodic pitch error and its causes.
4. thread progressive pitch error and its causes.

86
 87

Describe using a neat sketch…

1. How can the pitch of an internal thread be measured?

2. The followed procedure to measure the pitch of an external thread
using the T.M.M.
3. Two different techniques to avoid the occurrence of the shadow
when measuring the pitch diameter of an external thread on the tool
maker’s microscope.
4. An experimental method to measure the major diameter of an
internal thread.
5. An experimental method to measure the pitch diameter of an
internal thread.

87
Problems

88
88
1) An external thread of ISO metric form has the following dimensions and errors: Simple
effective diameter = 21.905 mm, Pitch =3.000 mm, Max. Pitch error = 0.025 mm, Right hand
flank error = 5 min of an arc and the left hand flank error = 6 min. Determine the virtual
effective diameter of the given thread.

Solution:
∆𝑫𝒆𝟏 = 𝟎. 𝟎𝟏𝟑𝟏 ∗ 𝑷 ∗ 𝜹𝜽𝑹𝒊𝒈𝒉𝒕 + 𝜹𝜽𝑳𝒆𝒇𝒕
For ISO metric thread, δθ in degrees and P = nominal pitch mm ➔ ∆𝑫𝒆 in mm.
∆𝑫𝒆𝟐 = ∆𝑷𝒎𝒂𝒙. ∗ 𝒄𝒐𝒕𝜽

𝑫𝒗 = 𝑫𝒆 + ∆𝑫𝒆𝟏 + ∆𝑫𝒆𝟐

89
2) Three wire set of nominal size 1.35 mm was used to inspect the pitch diameter of M16*2
screw plug. The used external micrometer has a scale value of 0.01 mm, measuring range
25mm, and zero reading of 0.05mm. Knowing that the maximum and minimum
permissible allowance of the pitch diameter is +0.21 mm and -0.00 mm, determine the
extreme readings of the micrometer such that the readings correspond to the accepted
screw lies-in-between.

Solution:
S = De + d(1+cosecθ) - (P/2) cotθ

Extreme readings are:

S + 0.05 + 0.21 ➔ Max. Reading
S + 0.05 ➔ Min. Reading

90
3) Calculate the virtual effective diameter of M16*1.5 screw if the reading over three wires
placed over the thread is 17.019 mm. The wires having 1.35 mm diameter, the right and left
flank angles of the thread were 29.5 and 30.5 deg., and the pitch in mm of the thread when
checked along the teeth were:
1.502 1.496 1.504 1.501 1.500 1.503 1.495 1.502
If this screw is to fit in a nut having 14.260±0.035 mm pitch diameter, check whether the
screw will fit fully, partially or will not fit at all when engaged with the nut. If partial fit
exists; mention the last engaged tooth number.
Pitch no. Δ mm Δ cc m t mm
Solution:
1 +0.002 +0.002

2 -0.004 -0.002

3 +0.004 +0.002

4 +0.001 +0.003

5 0.000 +0.003

6 +0.003 +0.006

7 -0.005 +0.001

8 +0.002 +0.003 91
De = S – d(1+cosecθ) + (P/2) cotθ
ΔPmax = (Max. +ve ∆P) – (Max. -ve ∆P)
ΔDe1 = ΔPmax * cotθ
ΔDe2 = 0.0131*P*( δθR + δθL)
Dv = De + ΔDe1 + ΔDe2
Dv > 14.295mm
Therefore, the nut will either partially fit or it won’t fit at all.

1st tooth → ΔDe = 0.002 * cot30 = 0.003mm

Dv = De + 0.003 + ΔDe2 < 14.295mm ➔ Therefore; the nut will fit

2 teeth → ΔDe = 0.004 * cot30 = 0.007mm

Dv = De + 0.007 + ΔDe2 = 14.295 mm ➔ Therefore; the nut will just pass

3 teeth → ΔDe = 0.004 * cot30 = 0.007mm

Dv = De + 0.007 + ΔDe2 = 14.295 mm ➔ Therefore; the nut will just pass

4 teeth → ΔDe = 0.005 * cot30 = 0.009mm

Virtual Dv > 14.295mm ➔ Therefore; the nut won’t pass
The nut will fit the first 3 teeth only
92
4) On a T.M.M. the pitch of a screw was measured, and the readings
(mm) were as follows:
1st. Side 5.02 7.04 9.05 11.03 13.00 14.98 17.02 19.04 21.00 23.03
2nd. Side 6.01 8.03 10.05 12.05 14.02 16.05 18.03 20.05 22.07 24.07
If the screw is a perfect screw in other parameters and it’ll fit a
perfect nut of 10 mm height. Will this screw engage fully with the
nut or partially, and if partially how many teeth will be engaged?
Given that the permissible allowance of the pitch diameter is ±0.06
mm. Thread std. pitch equals 2 mm.

Solution:

93
For the first 5 teeth the maximum accumulated error = 0.04mm ➔ ΔDe ˃ Permissible allowance
1st. tooth ➔ ΔDe < Permissible allowance ➔ The nut will pass
2 teeth ➔ ΔDe < Permissible allowance ➔ The nut will pass
3 teeth ➔ ΔDe < Permissible allowance ➔ The nut will pass
4 teeth ➔ ΔDe ˃ Permissible allowance ➔ The nut will not pass
The nut will fit the first 3 teeth only 94
5) In measuring the pitch diameter of a 52*5 mm metric plug screw gauge, the averages of the
readings taken were:
Reading over standard cylinder = 25.0033 mm
Diameter of standard cylinder = 15.0030 mm
Readings over each of the three wires = 13.2007, 13.2002 and 13.2000 mm
Readings over thread with the three wires in three different places= 64.0272, 64.0270 and
64.0275 mm.
a) Calculate the corrections for rake and compression errors, assuming a measuring force of
2.45 N.
b) Calculate the effective diameter, taking into consideration the calculated rake and
compression errors.

95
Solution:
Zero reading = 10.0003 mm
Reading over wires = S = De + d (1+cosec𝜃) - 𝑃/2 𝑐𝑜𝑡θ
De = S - d (1 + cosec 𝜃) + 𝑃/2 𝑐𝑜𝑡𝜃

Corrected De = De – Rake error + Compression error

𝑐𝑜𝑠𝜃𝑐𝑜𝑡𝜃 𝑙2
Rake error = ∗ 𝐴2 1 + 𝐴𝑠𝑖𝑛𝜃 + 𝐴2 𝑠𝑖𝑛2 𝜃 ➔ mm
∗
2𝜋2 𝑑
Where: 𝜃=Half the included angle, l = lead, d = wire diameter, T= reading under wires = S-2d,
A = d/(T+d).
2
𝐹3
Compression error = 0.001 ∗ 1 ➔ mm
𝐷𝑒3
Where: F= measuring force in N, De = Pitch diameter in mm

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Questions?